Production Engineering (2) – Production Eng. & Design Dept.
Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
CHAPTER 3: LATHE MACHINE
3.1 INTRODUNCTION Lathe is one of the most versatile and widely used machine tools all over the world. The main function of a lathe is to remove metal from a job to give it the required shape and size. Fig. 3.1 shows the working principle of lathe. Lathe can be used to carry out other operations also, such as drilling, reaming, boring, taper turning, knurling, screw thread cutting, grinding etc.
Fig. 3.1: Working principal of lathe machine
3.2 TYPES OF LATHE Lathes are manufactured in a variety of types and sizes, from very small bench lathes used for precision work to huge lathes used for turning large steel shafts. 1. Centre Lathe or Engine Lathe 2. Bench Lathe 3. Tool Room Lathe 4. Capstan and Turret Lathe 5. Special Purpose Lathes 6. Automatic Lathes Centre Lathe or Engine Lathe An engine lathe is shown in Fig. 3.2. Unlike the speed lathe, the engine lathe can feed the cutting tool both in cross and longitudinal direction with reference to the lathe axis with the help of a carriage, feed rod and lead screw.
Fig. 3.2: Principal components of a central lathe
1 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
3.3 CONSTRUCTION OF LATHE MACHINE
A simple lathe comprises of a bed made of grey cast iron on which headstock, tailstock, carriage and other components of lathe are mounted. Fig. 3.3 shows the different parts of engine lathe or central lathe. The major parts of lathe machine are given as under: 1. Bed 2. Head stock 3. Tailstock 4. Carriage 5. Feed mechanism 6. Thread cutting mechanism
Fig. 3.3: Different parts of engine lathe or central lathe
Fig. 3.4 shows the tail stock of central lathe, which is commonly used for the objective of primarily giving an outer bearing and support the circular job being turned on centers.
Fig. 3.4: Tail stock of central lathe.
2 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila The tool post is an important part of carriage, which fits in a tee-slot in the compound rest and holds the tool holder in place by the tool post screw. Fig. 3.5 shows the tool post of centre lathe.
Fig. 3.5: Tool post of centre lathe
Feed mechanism is the combination of different units through which motion of
headstock spindle is transmitted to the carriage of lathe machine. Following units play role in feed mechanism of a lathe machine: 1. End of bed gearing 2. Feed gear box 3. Lead screw and feed rod 4. Apron mechanism The half nut or split nut is used for thread cutting in a lathe. It engages or disengages the carriage with the lead screw so that the rotation of the leadscrew is used to traverse the tool along the workpiece to cut screw threads.
3.4 ACCESSORIES AND ATTACHMENTS OF LATHE
There are many lathe accessories provided by the lathe manufacturer along with the lathe, which support the lathe operations. The important lathe accessories include centers, catch plates and carriers, chucks, collets, face plates, angle plates, mandrels, and rests. Lathe centers The most common method of holding the job in a lathe is between the two centers generally known as live centre (head stock centre) and dead centre (tailstock centre). Carriers or driving dog and catch plates These are used to drive a job when it is held between two centers. Carriers or driving dogs are attached to the end of the job by a setscrew. A use of lathe dog for holding and supporting the job is shown in Fig. 3.6.
Fig. 3.6: Lathe dog
3 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
Chucks
Chuck is one of the most important devices for holding and rotating a job in a lathe. It is basically attached to the headstock spindle of the lathe. There are a number of types of lathe chucks, e.g. 1. Three jaws or universal 2. Four jaw independent chuck 3. Magnetic chuck 4. Collet chuck 5. Air or hydraulic chuck operated chuck 6. Combination chuck 7. Drill chuck.
Face plates
Face plates are employed for holding jobs, which cannot be conveniently held between centers or by chucks. A face plate possesses the radial, plain and T slots for holding jobs or work-pieces by bolts and clamps.
Angle plates
Angle plate is a cast iron plate having two faces machined to make them absolutely at right angles to each other.
Mandrels
A mandrel is a device used for holding and rotating a hollow job that has been previously drilled or bored. The job revolves with the mandrel, which is mounted between two centers.
Rests
A rest is a lathe device, which supports a long slender job, when it is turned between centers or by a chuck, at some intermediate point to prevent bending of the job due to its own weight and vibration set up due to the cutting force that acts on it. 3.5 SPECIFICATION OF LATHE The size of a lathe is generally specified by the following means: (a) Swing or maximum diameter that can be rotated over the bed ways (b) Maximum length of the job that can be held between head stock and tail stock centres (c) Bed length, which may include head stock length also (d) Maximum diameter of the bar that can pass through spindle or collect chuck of capstan lathe. Fig. 3.7 illustrates the elements involved in specifications of a lathe.
4 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
A - Length of bed. B - Distance between centres.
C - Diameter of the work that can be turned over the ways. D - Diameter of the work that can be turned over the cross slide. Fig. 3.7: Specifications of a lathe 3.6 LATHE OPERATIONS The various important lathe operations are depicted through Fig. 3.8 (a), (b) and (c), (d).
Fig. 3.8(a): Lathe operation
The operations performed in a lathe can be understood by three major
categories: (a) Operations, which can be performed in a lathe either by holding the workpiece between centers or by a chuck are: 1. Straight turning 2. Shoulder turning 3. Taper turning 4. Chamfering 5. Eccentric turning 6. Thread cutting 7. Facing 8. Forming 9. Filing 10. Polishing 11. Grooving 12. Knurling 13. Spinning 14. Spring winding (b) Operations which are performed by holding the work by a chuck or a faceplate or an angle plate are: 1. Undercutting 2. Parting-off 3. Internal thread cutting 4. Drilling 5. Reaming 6. Boring 7. Counter boring 8. Taper boring 9. Tapping
5 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
Fig. 3.8(b): Lathe operations
(c) Operations which are performed by using special lathe attachments are: 1. Milling 2. Grinding
Fig. 3.8(c): Lathe operation
6 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
Fig. 3.8(d): Other machining operations on centre lathe
3.7 TAPERS AND TAPER TURNING
In a lathe machine, taper turning means to produce a conical surface by gradual reduction in diameter from a cylindrical job. The compound rest can easily be swiveled or rotated and clamped at any desired angle as shown in Fig. 3.9 (a).
Fig. 3.9(a): Taper turning by swiveling compound rest
7 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila The complete setup for producing a taper by swelling the compound rest is given in Fig. 3.9(b).
Fig. 3.9(b): Swiveling compound rest set-up
This method is commonly employed for generating external tapers only. In this method, the taper turning attachment is bolted back of the lathe machine as shown in Fig.3.10.
Fig. 3.10: Taper turning using combined feeds
Taper turning can also be cut by combining the two feeds. Fig. 3.10 shows this arrangement of taper turning, which is good method of taper turning. The combined feed is made with the movement of a tool in longitudinal and lateral direction simultaneously while moving the workpiece.
The taper, which we are going to obtain, is equal to the resultant to the magnitude of the longitudinal and lateral feeds. Changing the feeds rates in both directions can change the direction and the taper angle. This method is basically employed for turning small tapers on longer jobs and is confined to external tapers only. In this method, the tailstock is set over is calculated using Fig. 3.11 by loosening the nut from its centre line equal to the value obtained by formula given below. 8 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
Fig. 3.11: Tailstock set over
Fig. 3.12 shows this method in which a taper form is used to obtain tapers. It is limited to short external tapers. The edge tool must be exactly straight for accurate work.
Fig. 3.12: Form tool taper turning
3.8 THREAD CUTTING Fig.3.13 shows the setup of thread cutting on a lathe. Thread of any pitch, shape and size can be cut on a lathe using single point cutting tool. Thread cutting is operation of producing a helical groove on spindle shape such as V, square or power threads on a cylindrical surface.
Fig. 3.13: Thread cutting
9 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
3.9 DRILLING ON A LATHE
The drill is held in the position of tailstock and which is brought nearer the job by moving the tailstock along the guide ways, the thus drill is fed against the rotating job as shown in Fig. 3.14.
Fig. 3.14: Drilling on lathe
3.10 Knurling operation: It is an operation of obtaining a diamond shape on the workpiece for the gripping purpose. This is done to provide a better gripping surface when operated by hands. It is done using a knurling tool. The tool consists of a set of hardened steel roller, and it is held rigidly on the tool post (Fig. 3.15).
Fig. 3.15: Knurling Operation
Knurling is done at the lowest speed available on a lathe. It is done on the handles and also in case of ends of gauges. The feed varies from 1 to 2 mm per revolution. Two or three cuts may be necessary to give the full impression.
3.11 Forming: It is the process of turning a convex, concave or of any irregular shape. Form- turning may be accomplished by the following method (Fig. 3.16): 1 Using a forming tool. 2 Combining cross and longitudinal feed. 3 Tracing or copying a template.
10 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
Fig. 3.16: Forming Operation
3.12 Machine Formula The following are the lathe machine formula commonly used to calculate in turning operations (Fig. 3.17): 1 Cutting speed 2 Feed 3 Depth of cut 4 Machining time
Fig. 3.17: Cylindrical turning on centre lathe
1. Cutting Speed
The cutting speed (v) of a tool is the speed at which the metal is removed by the tool from the workpiece. In a lathe, it is the peripheral speed of the work past the cutting tool expressed in meters per minute. Where, d – Is the diameter of the work in mm? n – Is the r.p.m of the work?
In the British system, cutting speed is expressed in feet per minute and diameter of the work in inches. Where, d – is the diameter of the work in inches, and n – is the r.p.m of the work.
11 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila The cutting speed, direction of feed and depth of cut to be given to a workpiece are shown in the figure below. Example 1 A steel shaft of 25mm diameter is turned at a cutting speed of 50 metres per minute. Find the r.p.m. of the shaft. In practice, when the calculated speed is not available in the machine the next lower value is selected.
2. Feed The feeds of the cutting tool in lathe work are the distance the tool advances for each revolution of the work. A feed is expressed in millimetres per revolution. In the British system, it is expressed in inches per revolution. Increased feed reduces cutting time. But increased feed greatly reduces the tool life. The feed depends on factors such as size, shape, strength and method of holding the component, the tool shape and it’s setting as regards overhang, the rigidity of the machine, depth of cut, power available, etc. rougher feeds are applied for roughing and finer feeds for finishing cuts.
3. Depth of Cut
The depth of cut (t) is the perpendicular distance measured from the machined surface to the uncut surface of the workpiece. In a lathe machine, the depth of cut is shown as follows: Where,
d1 – diameter of the workpiece surface before machining.
d2 – diameter of the machined surface.
4. Machine Time The machining time in the lathe work can be calculated for a particular operation if the speed of the job, feed and length of the job is known. If “s” is the feed of the job per revolution expressed in mm per revolution and “l” the length of the job in mm, then a number of revolutions of the job required for a complete cut will be: l/s.
Therefore, the time is taken for a complete cut = l / s X n min.
12 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila If the r.p.m. of the work is n, the time is taken to revolve the job through l/s number of revolutions for a complete cut will be: Example 2 Find the time required for one full cut on a workpiece of 350mm long and 50mm in diameter. The cutting speed is 35 metres per minute and the feed is 0.5mm per revolution. Average cutting speed expressed in meter per minute for different operations in a lathe using an H.S.S. tool
3.13 Types of Chuck in the Lathe Machine:
A Lathe chuck is one of the most important devices in the lathe machine it is used for holding and rotating a piece of work while performing a lathe operation. The workpiece of short length and large diameter of irregular shape which cannot be conveniently mounted between centres are held quickly and rigidly in a chuck.
Fig. 3.18: (a) Holding the work between centers, (b) chuck, (c) collet, and (d) face plate
13 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
1- Four-Jaw Independent Chuck
The figure 3.18 shows a four jaw chuck diagram. The arrangement of four jaws independent chuck, which has four jaws, located at an angle of 90° to each other. Here all the four jaws are opened independently. Here four screws are used in place of scroll disk, Hence it is called as four jaw independent chuck. Each jaw made of tough steel has three inner and one outer gripping surface. The outer gripping surface is used for holding larger sizes of the workpiece by reversing the jaw (Fig. 3.19):
Fig. 3.18: A Four Jaw Chuck Fig. 3.19: A Four Jaw Chuck 2- Universal or Three Jaw Chuck A three-jaw chuck is shown in the figure. This is the most commonly used types of chuck in the lathe machine. The three jaws are generally made of high-quality steel and are arrogated at an angle of 120° to each other (Fig. 3.20). During the operation, the jaw teeth are made to mesh with scrawl spiral teeth (Bevel teeth). The meshing causes a moment of all three jaws either towards or away from the chuck centre, depending upon the direction of rotation of the bevel pinion. The pinion is operated by square end key called “chuck key” (Fig. 3.21).
Fig. 3.20: A three-jaw chuck Fig. 3.21: A three-jaw chuck
3- Combination Chuck As the name implies, a combination of chuck, as shown in Figure. It is used both as a self-centering and an independent chuck to take advantage of both the types (Fig. 3.22 a, b).
14 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
(a) (b) Fig. 3.22: A combination of chuck 4- Magnetic Chuck The chuck is used for holding a very thin workpiece made of magnetic material which cannot be held in an ordinarily chuck. It is also used where any distortion of the workpiece due to the pressure of the jaws is undesirable (Fig. 3.23). The holding power of the chuck is obtained by the magnetic flux radiating either from the electromagnets or from the permanent magnets introduced within the chuck.
Fig. 3.23: A Magnetic Chuck
5- Collet Chuck Collet chucks are used for holding bar stock in production work where quick setting and accurate centring is needed (Fig. 3.24). The chuck attached to the spindle by a nut consists of a thin cylindrical bushing known as collet having a slots cut lengthwise on its periphery. The inside bore of the collet is cylindrical, hexagonal, square, etc. Depending on the shape of the work that will pass through it.
Fig. 3.24: A Magnetic Chuck
15 Production Engineering (2) – Production Eng. & Design Dept. Faculty of Engineering Minia University- by Assoc. Prof. Helmi Abulila
6- Drill Chuck A drill chuck is sometimes used in a lathe for holding straight shank drill, reamer, or tap for drilling, reaming, or tapping operation. The chuck is held either in headstock or tailstock spindle. It has centering jaws which have operated by rotating a key (Fig. 3.26).
Fig. 3.26: A drill chuck
3.14 QUESTIONS 1. Describe the working principle of the lathe. 2. Name the different types of the lathes available in machine shop? Describe the working of a center lathe. 3. Explain the parts of a center lathe using neat sketch. 4. Explain following parts of a lathe by neat sketches: (i) Lathe Bed (ii) Carriage (iii) Headstock (iv) Tailstock 5. How can you specify a lathe? 6. Name the operations, which can be performed on a lathe. 7. Lists the accessories of a lathe? Explain them with neat sketches. 8. Describe any two work holding devices used on the lathe. 9. What is the use of follower rest and steady rest? 10. Explain the difference between three jaw chuck and four jaw chuck. 11. Using neat sketches, describe the various operations that can be carried on lathe machines. 12. With the help of a line diagram, describe the gear mechanism of an engine lathe. 13. Discuss the merits and demerits of a geared-head drive over cone-pulley drive. 14. Name and sketch the different types of the cutting tools of the lathe. 15. Describe the procedure of cutting right hand V- heads of the lathe. 16. With help of neat diagram, describe the following: (i) Finish turning (ii) Rough turning (iii) Turning (iv) Drilling (v) Attachments of lathe 17. Name different methods of taper turning? Describe these methods using neat sketches. 18. Describe with suitable sketch the procedure for turning a taper using setting over the tailstock. 19. Define the following terms used in lathe operation. (i) Cutting speed (ii) Feed (iii) Depth of cut (iv) machining time.
